Color projection system with a color correction wedge

ABSTRACT

An embedded polarizing beamsplitter employed in a liquid crystal light valve color projector introduces lateral chromatic aberration of complex distribution that degrades contrast and resolution of the projected image. Color correction is provided to substantially eliminate any noticeable lateral chromatic aberration by replacing the output window of the prism with an optical wedge made of the same material as the embedded prism plate of the beamsplitter.

This is a division of application Ser. No. 137,486, filed Dec. 22, 1987,now U.S. Pat. No. 4,890,901.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to embedded prisms, and more particularlyconcerns correction of lateral chromatic aberration of light transmittedthrough such an embedded prism.

2. Description of Related Art

A type of beamsplitter widely used for selectively passing andreflecting a light beam includes a thin, flat, parallel sided,transparent plate mounted in a transparent liquid or solid medium at anangle, commonly about 45°, to the axis of a beam of light that is to betransmitted or reflected. Such beamsplitters may be polarizing ornonpolarizing. A polarizing beamsplitter, but not of the embedded type,is described in U.S. Pat. No. 2,403,731 issued to MacNeille. Thepolarizing beamsplitter, such as the MacNeille type polarizingbeamsplitter will pass light having one polarization state, such as the"P" state for example, and reflect light with another polarizationstate, such as the "S" state for example. Thus, the polarizingbeamsplitter selectively passes or transmits a light beam, dependingupon whether the polarization vector of the light is one or the other oftwo mutually orthogonal directions. In the beamsplitter described in theMacNeille patent, a plurality of dielectric layers of appropriateindices of refraction and thicknesses are deposited at the interfacebetween the two halves of a glass cube of which the mating interfaceextends diagonally between two diagonally opposite edges of the cube.

In an embedded MacNeille polarizing beamsplitter, a housing of generallycubic configuration is provided with transparent front, back, entranceand exit windows. This is filled with a fluid in which is suspended aprism plate comprising a thin plate with mutually parallel planar sidesthat extends diagonally across the cube. A plurality of thin dielectriclayers, of the type described in the MacNeille patent, may be applied tothe thin plate to make this embedded prism a MacNeille polarizing prism.Such embedded prisms exhibit a color defect known as lateral chromaticaberration, which significantly decreases clarity and resolution oftransmitted light and also significantly reduces contrast, therebyproducing an image of decreased quality. This aberration is due to thedifferent variation of index of refraction with color from one materialto another, as will be explained below.

To avoid bending of the light transmitted through the embedded prismplate, the prism and the fluid in which it is immersed are made ofmaterials selected to have matching indices of refraction. As is wellknown, the index of refraction of a material is proportional to thereciprocal of the velocity of light propagated in the material, and suchvelocity varies from one material to another. Thus, as the light passesfrom one material to another with a different index of refraction, thelight beam is bent. Accordingly, an embedded prism must be constructedwith materials having the same index of refraction insofar as possible,if beam bending is not desired. However, the index of refraction of anygiven material varies non-linearly with the wavelength of the light orits color. Accordingly, when matching indices of refraction of twomaterials, it is common to employ the peak visual wavelength, green,which has a wavelength of about 550 nanometers (550×10⁻⁹ meters or 0.55micrometers, which is approximately 21.7 microinches) when comparingindices of refraction. Nevertheless there exists for each material anunique, non-linear color sensitive variation (from one wavelength toanother) of its index of refraction. The non-linear variation of indexof refraction with color (wavelength) itself varies from one material toanother, even if the indices of the two materials are the same at somegiven wavelength. Therefore, although two materials may be selected tohave nominally equal indices of refraction, in actual fact the indicesof refraction are equal only at the particular "match" wavelength.

Refraction of a component of light at an interface between two mediadepends upon both the difference in indices of refraction of the mediaand the angle of incidence of the light upon the interface. When aconverging or diverging beam of light is directed at thereflection/transmission interface, generally inclined at 45° to the axisof the incident beam in a beamsplitter, the angle of incidence ofdifferent rays of the same beam on the interface varies as the distanceof the point of impingement of the ray from the center line of the lightbeam increases.

The described lateral chromatic aberration is a color distortion that isnot uniform over the field of the light beam, but generally increaseswith increasing distance from the optical axis. At any given distancefrom the optical axis, in any direction, the magnitude of this chromaticaberration is generally the same.

Past efforts to minimize adverse effects of such lateral chromaticaberration of embedded prisms have generally been directed towardselection of materials having indices of refraction that not only matchat a given wavelength, such as 550 nanometers, but in which, for onematerial, the non-linear variation of the refracted index with color iseither of a minimal value or also closely matches the non-linearvariation of index of refraction of the other material. Complete andsatisfactory avoidance of this problem has not been achieved in thepast, even with the use of very expensive materials, such as fusedsilica for the prism plate and a specifically manufactured fluid, suchas Cargille standard fused silica matching liquid, code 50350.

Although the embedded prism polarizing beamsplitter, e.g. an embeddedMacNeille type polarizing beamsplitter, is useful in a wide variety ofapplications, one example of such an application is a color projectionsystem employing a liquid crystal light valve. Examples of suchprojection systems are described in U.S. Pat. No. 4,343,535 to Bleha,Jr. and in U.S. Pat. No. 4,650,286 to Koda et al. A color projectionsystem of this type is made and sold by Hughes Aircraft Company asHDP-6000 Model 700. The model 700 series of this projection system usesan embedded prism polarizing beamsplitter having a fused silica T12OPTOSIL prism plate having an index of refraction of 1.459723 at 554.5nanometers suspended in the Cargille code 50350 fluid. Hughes AircraftCompany HDP-6000 color projection system Models 800 and 1000 use a prismplate of Schott BK7 glass having an index of refraction of 1.518298 at554.5 nanometers and a Cargille code 1160 fluid having an index ofrefraction of 1.517903 at the same wavelength. In such a colorprojection system, as described in detail in these patents, light from alight source is reflected from a MacNeille prism to a liquid crystallight valve which causes the light valve to retroreflect light of aparticular polarization in accordance with modulation imposed on thelight valve by an image generator, such as a cathode ray tube. Theuniquely polarized light modulated and retroreflected from the lightvalve is then transmitted through the embedded MacNeille prism andprojected via a projection lens. Transmission of the polarized lightthrough the embedded MacNeille prism is subject to the above-describedcolor aberration, despite the selection of expensive materials for theembedded MacNeille prism, whereby contrast and resolution of theresulting projected image is significantly degraded.

Accordingly, it is an object of the present invention to provide colorcorrection for an embedded prism.

SUMMARY OF THE INVENTION

In carrying out principles of the present invention, in accordance witha preferred embodiment thereof, an embedded prism includes a prism bodyformed of a first material, and prism means mounted within the body-forming an interface with the body and being formed of a second materialhaving an index of refraction substantially equal to the index ofrefraction of the material of the body at a selected wavelength. Lightentering the prism body is transmitted to an exit area through the prismmeans, but is subject to color aberration. Correcting means are coupledwith the prism body for correcting the transmitted light beam for thecolor aberration. In accordance with one specific embodiment of theinvention, the correcting means comprises a correcting wedge mounted inthe exit area. According to another feature of the invention, thecorrecting wedge is formed of a material having the same index ofrefraction as the index of refraction of the prism means.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIG. 1 illustrates a liquid crystal light valve color projector of theprior art employing a MacNeille prism without color correction;

FIG. 2 illustrates a liquid crystal light valve color projector having aMacNeille prism with a color corrector exit prism; and

FIGS. 3, 4 and 5 illustrate respective modifications of the colorcorrected MacNeille prism shown in FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a liquid crystal light valve color projection systemof the type generally shown in U.S. Pat. No. 4,343,535 to Bleha, Jr. andU.S. Pat. No. 4,650,286 to Koda et al. Briefly, this color projectionsystem embodies a light source 10 that emits unpolarized light that istransmitted through a collimating lens 12 which directs the light beam14 to a prism plate 16 of an embedded version 18 of a MacNeille prism.The MacNeille prism is a polarizing beamsplitter which accomplishesselective polarization, as generally described in the patent toMacNeille, 2,403,731. The embedded MacNeille-type prism 18,schematically depicted in FIG. 1, comprises a parallel flat sidedtransparent prism plate 16 coated with a plurality of thin, dielectriclayers as described in the MacNeille patent No. 2,403,731, and suspendedin a prismatic fluid 20, all carried in a fluid-tight housing generallyindicated at 22, having a transparent front window 24 and a transparentexit window 26.

The polarizing beamsplitter 18 includes an input window 28 through whichit receives randomly polarized light from source 10, transmits light ofone polarization, such as the "P" polarization for example, and reflectslight of another polarization state, such as the polarization state "S"for example.

Reflected light of "S" polarization state travels along a reflected beam32 to a liquid crystal light valve 34 that is modulated by an imagegenerating source, such as a cathode ray tube 36. Where the screen ofthe cathode ray tube 36 has no phosphor emission and is therefore dark,the corresponding area of the light valve 34 remains in an off state,and light is retroreflected from the light valve 10 back to thepolarizing prism with its polarization state unchanged. Because thepolarization of the light is unchanged from its original "S" state,light is again reflected from the beamsplitter prism plate and returnsto the light source 10. None of this light of polarization state "S" istransmitted by the prism plate from the light valve 34 to the projectionlens, and thus the corresponding areas imaged by a projection lens 38remain dark. For those phosphor areas of the screen of the cathode raytube 36 that are bright, some or all of the light reflected from thelight valve 34 is rotated from "S" polarization state to "P"polarization state, and acquires an intensity proportional to theintensity of the light from the cathode ray tube screen. This light ofpolarization state "P" is retroreflected by the light valve 34 andtransmitted through the polarizing beam splitter 18, passing through thebeamsplitter exit window 26 and projection lens 38 to form a brightimage on a projection screen (not shown).

The described projection system is subject to a problem thatsignificantly degrades both contrast and resolution of the projectedimage. This error is unique to the embedded prism, and is primarily dueto differences of the non-linearity of variation of index of refractionof the two adjacent materials, material of the prism plate 16 andmaterial of the fluid 20. As previously mentioned, index of refractionof the material varies from one wavelength to another. Materials of theprism plate 16 and fluid 20 are selected to have the same index ofrefraction at a given wavelength, generally at the peak of the visualspectrum, or green, which has a wavelength of about 550 nanometers. Notonly are the materials selected to have the same index of refraction atthe visual peak, but, because the index of refraction varies withwavelength (or color), materials are chosen such that variation of theindex of refraction for each with wavelength will be as close to oneanother as possible in the two materials. For this reason, namely todecrease lateral chromatic aberration caused by difference innon-linearities of variation of index of refraction with color of thetwo adjacent materials of the prism, a fused silica is commonly used forthe prism plate 16, and an unique fluid, such as the Cargille code50350, is chosen as a best match of indices of refraction over thevisual spectrum. Nevertheless, despite best efforts to employ materialshaving matching indices of refraction, and despite the expense involvedin use of relatively uncommon materials, non-linearities of thevariations of the indices of refraction cannot be precisely matched sothat resolution and contrast continue to be degraded.

The effect of the lateral chromatic aberration introduced by thenon-matching indices of refraction is heuristically illustrated in FIG.1, which shows a single light ray 50 transmitted from light valve 34impinging upon the prism plate fluid interface 52 (which is inclined atan angle of 45° with respect to the optical axis of beam 32). Colorcomponents of this white light ray 50 are differently refracted, tothereby separate the color components as indicated by the red ray 54 andthe blue ray 56. Similarly, a light ray 60 retroreflected from theliquid crystal light valve impinges on the interface 52 and the colorcomponents of its white light are differently refracted to provide thered ray 64 and blue ray 66. The differently diffracted color componentrays 54,56, 64,66 are transmitted to the projection lens 38 to form aprojected beam having significant color aberration, and therefore havingsignificantly decreased resolution and contrast. The magnitude of thedescribed aberration increases with increase of thickness of plate 16.Therefore, the plate 16, which must have at least a minimum thickness of1/30th to 1/15th of its length (at least for structural andfabricational considerations), is usually made as thin as possible todecrease the color aberration. Current commercial prism plates of BK7glass are about 0.125-inches thick (1/34th of length) and yet are aboutas thin as can be economically made. Plates this thin still produceunacceptably large lateral chromatic aberration at the prescribedincidence angle (54.6°).

The lateral chromatic aberration in the embedded prism as describedabove is primarily due to the lack of match of indices of refraction ofthe fluid 20 and the material of the prism plate 16. The effect is alsoa function of the angle of incidence, as there is infinitesimalaberration when the light beam axis is directed along a perpendicular tothe interface. Moreover, the effect is more pronounced when theimpinging light beam is converging or diverging. On the axis of theincident light beam the color aberration effect is relatively small, butthe error increases, in a non-linear fashion, with increasing distancefrom the optical axis.

Applicant has discovered, surprisingly and unexpectedly, that thedescribed lateral chromatic aberration in the embedded prism can besubstantially completely corrected by the substitution of a wedge forthe exit window 26. One reason for surprise at the simplicity of thecorrection is the complexity of the aberration. The lateral chromaticaberration present is not the usual type of aberration which is radiallysymmetric about the optical axis. Instead, an aberration vector mapsweeps out a "Lemniscate of Bernouli," or the two-leaved rose. Thus, asillustrated in FIG. 2, a liquid crystal light valve color projectionsystem, corrected for lateral chromatic aberration introduced by theembedded polarizing prism is arranged substantially identically as thesystem of FIG. 1, with only the substitution of an optically transparentwedge 127 for the exit window 26. In FIG. 2, elements that are identicalto comparable elements of FIG. 1 are denoted by the same referencenumerals with the prefix 1. Thus, light source 10 of FIG. 1 correspondsto light source 110 of FIG. 2, and prism plate 16 of FIG. 1 correspondsto prism plate 116 of FIG. 2, etc. The system of FIG. 2 operates in thesame manner as the system of FIG. 1. However, the exemplary dispersedlight rays 154,156, differently refracted because of the non-matchingindices of refraction of fluid 120 and prism plate 116, are recombinedby wedge 127 which is positioned at the exit area of the MacNeille prism118. This results in a single combined white ray 170 for dispersed rays154,164 and in a single combined white ray 172 for the dispersed colorcomponent rays 156,166. It will be understood, of course, that thedispersion of the rays and the various angles illustrated in thedrawings are exaggerated for purposes of illustration. Therefore, withthe exit window taking the form of wedge 127, the chromatic aberrationproduced by the embedded prism is effectively eliminated so thatcontrast and resolution of the resulting projected image aresignificantly improved.

Material of the color correcting prism 127 is chosen to have indices ofrefraction for all colors as close as possible to the indices ofrefraction of the prism plate 116. Most conveniently this is achieved bymaking the color correcting wedge 127 of the same material as prismplate 116. The inwardly facing, downwardly and inwardly inclined surface174 of wedge 127 is in contact with the fluid 120, just as are bothsurfaces of the prism plate 116 (or its coatings). Depending onparticular materials involved, and as a specific example with materialsused for the fluid 120 and prism plate 116 as described above, the angleof the wedge, that is, the inclination of inwardly facing surface 174with respect to the opposite (external) surface 180 of the colorcorrecting prism, is between 2° and 4°. Best results have been achievedwith a wedge angle of about 3° for these materials, when the optimumangle of incidence (54.6°) for the polarizing plate has been used.

Tests of the color correction for the described color projection systemhave shown a dramatic improvement as compared to prior systems, whichare otherwise identical except for the lack of the color correctingprism. Absence of annoying color fringes, which existed in the priorsystems, produce a sense of greatly increased image quality. Tests haveshown that the amount of lateral chromatic aberration existing with apolarizing beamsplitter prism 118, of the type shown in FIG. 2, havingthe color correction wedge 127, is so small as to be negligible.Effectively, the color correcting wedge provides a full one hundredpercent correction. This is so because the residual amount of coloraberration is less than the color error in the projection lens, and thusfor all effective purposes the color correction is essentially perfect.

FIG. 3 illustrates a slight modification of the corrected embedded prismof FIG. 2 and shows the embedded prism 218 substantially similar to theprism 118 of FIG. 2, having a housing 222, a front window 224, and aninternal fluid 220 in which is suspended a prism plate 216, the prismbeing provided with a color correcting prismatic exit wedge 227, allsubstantially the same as described in connection with FIG. 2. However,to provide a further degree of adjustment of the amount of colorcorrection, or to provide effectively a fine tuning of the amount ofcolor correction, a thin, transparent plate 229 having parallel flatsides and a thickness in the order of one eighth to a quarter of an inch(a thin plate) is also suspended in the fluid 220 within the housing andpositioned between the correcting wedge 227 and the prism plate 216.Fine tuning plate 229 is positioned with its flat surfaces at an angleto a vertical line, as seen in FIG. 3, which may be somewhat greater orless than the angle between the inclined inner surface 274 of correctingwedge 227 and a vertical line. In the correcting wedges 127 and 227, theexternal surfaces 180 and 280 lie in a plane perpendicular to theoptical axis, whereas the inclined front or inwardly facing surfaces 174and 274 of each wedge extend at an angle of approximately 3° withrespect to a plane that is normal to the optical axis, as previouslydescribed. The plane of the surfaces of the fine tuning plate 229 thenmay extend at an angle to a plane normal to the optical axis that is adegree or a fraction of a degree more or less than the angle of surface274 of the correcting wedge. The angle of fine tuning plate 229 isdetermined empirically, and the material of the plate 229 is also chosento have the same index of refraction as that of the correcting wedge andthe prism plate 216. This can be most conveniently achieved by choosingthe same material for fine tuning plate 229 as used for the correctingwedge 227 and for prism plate 216. Tuning plate 229 changes theeffective color correction action of wedge 227.

As shown in the modification of FIG. 4, a corrected embedded prismincludes a prism plate 316 suspended in a fluid 320 in a housing havinga front window 324 and a rear window 326, which in this case hasparallel flat sides and provides no color correction. The colorcorrecting wedge in this embodiment is positioned between the prismplate 316 and the exit area window 326. In this case the main colorcorrection is provided by selection of the wedge angle of correctingwedge 329, and the fine tuning is effected by selecting the angle oftilt of the wedge 329 with respect to the optical axis 319. Thus, thecorrecting wedge 329 has a rear surface 380 that is inclined withrespect to a plane perpendicular to optical axis 319, and, moreover, hasa forwardly facing wedge surface 374 that extends at a selected angle,such as the above-described 3° with respect to the plane of the surface380.

In the arrangement of FIG. 5, an embedded prism includes a fluid 420 inwhich is suspended a prism plate 416, all mounted in a housing 422,having a front window 424 and a rear, flat, parallel sided window 426.Color correction in this arrangement is provided by suspending withinthe fluid 420 a thick plate 429 having flat, parallel sides 480,474. Inthe arrangement of FIG. 5, correction is provided by the parallel sidedcorrecting plate 429 because of its thickness and the angle of its facesrelative to the optical axis 419. The use of a thick plate, which isherein defined as a plate having a thickness of between about onequarter and one inch, achieves a correcting effect equivalent to theexit wedge 127 of FIG. 2 when suspended within the fluid 420 and tiltedat an appropriate angle, such as an angle of between 2° and 4°, forexample. It may be noted that the beam transmitted through the embeddedprisms of FIGS. 2, 3, 4 and 5 is not bent, because the index ofrefraction of the prism plate matches that of the embedded fluid at aselected wavelength.

Although the arrangements illustrated in FIGS. 2 through 5 all show thecorrecting elements in contact with a fluid having an index ofrefraction that matches, at least at one wavelength, the index ofrefraction of the correcting element, the principles of the inventionare applicable to use of a correcting wedge that is positioned outsideof the polarizing beamsplitter prism or other embedded prism. In such anarrangement, the embedded prism would take the configuration of theprior art prism illustrated in FIG. 1, having a parallel, flat sidedexit window 26. In this case the wedge, such as a wedge 127, would bemounted outside of the embedded prism between the prism and theprojection lens 138. In such an arrangement, the color correction wouldbe achieved in the manner and to the extent previously described inconnection with FIG. 2. However, because of the mismatch of impedancebetween the color correcting wedge and the air in which this correctingprism is now immersed in such a configuration, the optical beam is bentby the correcting wedge. If such beam bending can be tolerated orcorrected, the correcting wedge need not be mounted in contact with theindex matching fluid of the beamsplitter prism.

Although the embedded prism shown in FIG. 2 employs an index matchingfluid, the prism may also be made with a solid body in which is embeddeda solid, flat, parallel sided prism plate, like plate 116 of FIG. 2.This plate may be adhesively secured to the solid, transparent materialin which it is embedded. If the prism plate is made of a material otherthan that of the embedding solid, the system will exhibit the describedlateral chromatic aberration, which may be corrected by adhesivelysecuring a color correcting wedge at the prism exit area.

Although the invention has been described herein in connection with usein a polarizing beamsplitter prism forming part of a liquid crystallight valve color projection system, it will be readily appreciated thatthe principles of the invention are applicable to other types ofembedded prisms, whether liquid or solid, whether polarizing ornon-polarizing. For example, principles of the invention are applicablefor color correction of aberrations exhibited in multi-color lasersystems, where multiple colors are made colinear, co-planar, orparfocal. Thus, it will be seen that instead of requiring very costlymaterials for use as components of liquid prisms and other embeddedprisms, and instead of attempting to minimize thickness of the prism,all without obtaining satisfactory results, the lateral chromaticaberration can be readily corrected by use of a simple and inexpensivecorrecting wedge or tilted plate. Application of principles of theinvention therefore result not only in cost savings, but in significantimprovement in projected image quality.

Although the foregoing has been a description and illustration ofspecific embodiments of the invention, various modifications and changesthereto can be made by persons skilled in the art without departing fromthe scope and spirit of the invention as defined by the followingclaims.

What is claimed is:
 1. A color projection system comprising:a lightsource, a projection lens, a liquid crystal light valve, an imagegenerator for modulating light transmitted to said liquid crystal lightvalve, polarizing beamsplitter means interposed between said lightsource and said liquid crystal light valve and between said light valveand said projection lens for reflecting light from said light source tosaid liquid crystal light valve and for transmitting light reflectedfrom said valve to said projection lens, said polarizing beamsplittermeans having an optical axis and comprisinga prism body of a fluidhaving a first index of refraction at a selected wavelength, a parallelsided transparent plate suspended within said fluid for reflecting lightfrom said light source to said light valve and for transmitting lightfrom said light valve to said projection lens, said plate being formedof a solid material having a second index of refraction substantiallyequal to said first index of refraction at said selected wavelength,whereby light transmitted through said plate is subject to a complexlateral chromatic aberration that increases with increasing distancefrom the optical axis, and a color correction wedge interposed betweensaid plate and said projection lens in contact with said fluid forcorrecting light transmitted through said plate for said lateralchromatic aberration, said wedge being formed of a material having thesame index of refraction as said plate over a band of wavelengths. 2.The color projection system of claim 1 wherein said wedge has a firstface normal to said axis and a second face extending at an anglerelative to said first face of between about 2° and 4°.
 3. The colorprojection system of claim 2 wherein said wedge is formed of the samematerial as the material of said plate.